# A Rockdale Operations Standard Operating Procedure

Department Name: Engineering, Maintenance & Construction

Document Number: EMC

- SOP

- 2027 Page 1 of 7

Title: Control Plan for Line 6 Wet Scrubber System

ROCKDALE OPERATIONS

- SMELTING AND INGOT PAGE 1 OF 5

Document Number: PMT

- SOP

- 2005

Title: Control Plan For Line 3 Wet Scrubber System



### Controlled Document if Viewed On

- Line. If Printed, Valid for 24 Hours from Print Date/Time.

Pri nt Date/Time 2/6/2003 2/5/2003 1:57 PM 1:25 PM 12:59 PM 12:23 PM

Controlled Document if on BLUE PAPER or Viewed On

- Line. If Printed, (except BLUE PAPER) Valid

for 24 Hours from Print Date/Time.

Print Date/Time 5/27/2011 6/24/2004 6/15/2004 9:12 AM 10:00 AM 1:41 PM Special Hazards: Failure to follow procedures correctly and maintain proper eqipment parametrics

may result in equipment damage and/or a mact parametric exceedance.

Significant

Environmental

Aspect: Following this procedure will ensure that proper ste ps are taken to decrease

adverse impacts to the environment.

PREPARATION

TAG & LOCK

TRY . Always follow the proper tag, lock and try procedur e e

when performing maintenance repairs and/or

replacements where applicable.

CONFINED SPACE:

. Always follow the proper confine space entry procedure

w W hen performing maintenance repairs and/or

r R eplacements where applicable.

# A Rockdale Operations Standard Operating Procedure

Department Name: Engineering, Maintenance & Construction

Document Number: EMC

- SOP

- 2027 Page 2 of 7

Title: Control Plan for Line 6 Wet Scrubber System

ROCKDALE OPERATIONS

- SMELTING AND INGOT PAGE 1 OF 5

Document Number: PMT

- SOP

- 2005

Title: Control Plan For Line 3 Wet Scrubber System



### Controlled Document if Viewed On

- Line. If Printed, Valid for 24 Hours from Print Date/Time.

Pri nt Date/Time 2/6/2003 2/5/2003 1:57 PM 1:25 PM 12:59 PM 12:23 PM

Controlled Document if on BLUE PAPER or Viewed On

- Line. If Printed, (except BLUE PAPER) Valid

for 24 Hours from Print Date/Time.

Print Date/Time 5/27/2011 6/24/2004 6/15/2004 9:12 AM 10:00 AM 1:41 PM PROCEDURE TO:

Control Fan Amps

Water Flow

ESP’s

Outlet Emissions

Dust Collecting Hoppers NOT E: All Potroom Fume Control MACT parametric alarms must be acknowledged

within one hour of the time the alarm was initiated. All MACT exceedances and

malfunctions must be reported and documented within one hour of the initial

identification. I f any inspections and/or repairs are to be made, use all required tag,

lock, try and confine space entry procedures

where applicable.



### Fan Amps (MACT Parameter)

Operating Range ESP’S

. Minimum 1 8 2 9 Amps, Normal 1 61 102 Amps

Operating Range 13D1

. Minimum 177 Amps, Normal 222 Amps

Measurement Method

. Amp signal is indicated on computer control screen (Wonderware) and on a field

display (Panelview and analog meter) and analog meter.

. MACT compliance d ata values are indicated on computer screen (Access) and

values and trends are indicated on computer control screen (Wonderware).

Control Method

. Ensure fan damper is positioned for proper MACT parametric requirements.

Damper is automatically ful l open or full close.

Consequences of Deviation

. Below minimum parametrics can cause low potdraft, high potline roof emissions

and MACT parametric exceedances.

Corrective Action

. Exercise or open damper to keep within required MACT parametri c values.

Report problems to supervision. Refer to MACT Reaction Plan SOP’s for required

fan amps. If control device is below MACT compliance start another or an

additional fan(s).



### Water Flow (MACT Parameter) And pH Level

GPM Operating Range ESP’S

. Minimum 176 144 GPM, Normal 220 181 GPM

GPM Operating Range 13D1

. Minimum 188 GPM, Normal 235 GPM

pH Operating Range

. 8

- 10 at basin, 10

- 12 at clearwell

# A Rockdale Operations Standard Operating Procedure

Department Name: Engineering, Maintenance & Construction

Document Number: EMC

- SOP

- 2027 Page 3 of 7

Title: Control Plan for Line 6 Wet Scrubber System

ROCKDALE OPERATIONS

- SMELTING AND INGOT PAGE 1 OF 5

Document Number: PMT

- SOP

- 2005

Title: Control Plan For Line 3 Wet Scrubber System



### Controlled Document if Viewed On

- Line. If Printed, Valid for 24 Hours from Print Date/Time.

Pri nt Date/Time 2/6/2003 2/5/2003 1:57 PM 1:25 PM 12:59 PM 12:23 PM

Controlled Document if on BLUE PAPER or Viewed On

- Line. If Printed, (except BLUE PAPER) Valid

for 24 Hours from Print Date/Time.

Print Date/Time 5/27/2011 6/24/2004 6/15/2004 9:12 AM 10:00 AM 1:41 PM PROCEDURE TO:

Control Fan Amps

Wate r Flow

ESP’s

Outlet Emissions

Dust Collecting Hoppers

(continued) Measurement Method

. GPM signal is indicated on computer control screen (Wonderware) and on a

field display (Panelview and Panametric meter). PH signal is indicated on

comput er control screen (Wonderware) and field pH meter.

. MACT Compliance data values are indicated on computer screen (Access) and

values and trends are indicated on computer control screen (Wonderware).

Control Method

. Ensure water valves are p ositioned for proper MACT parametric requirements.

Ensure correct amounts of lime for proper pH levels.

Consequences of Deviation

. Below minimum parametrics can cause high outlet emissions and MACT

parametric exceedances. High and low levels of pH can cause inadequate

scrubbing and excess solids which leads to build

- up.

Corrective Action

. Excerise or open header valves to keep within required MACT parametric

values.

Always leave the main valve fully open. Report p roblems to supervision. Refer

to MACT Reaction Plan SOP’s for required fan amps. If control device is

below MACT compliance start another or an additional scrubber(s). Monitor

lime slaker operation and controls.



### ESP Primary Voltage (MACT Parameter)

Operating Range

. 110 Volts, No Normal

ESP Primary Voltage (MACT Parameter)

Operating Range

. 9 Mamps , No Normal

Measurement Method

. Volt signal is indicated on computer control screen (Wonderware ), on a field

BHA controller and an analog meter.

. MACT Compliance data values are indicated on computer screen (Access) and

values and trends are indicated on computer control screen (Wonderware).

Control Method

. Ensure precipitator i s on and primary voltage is above the required MACT

parametric minimum.

Consequences of Deviation

. Below minimum parametrics can cause high outlet emissions and MACT

parametric exceedances.

# A Rockdale Operations Standard Operating Procedure

Department Name: Engineering, Maintenance & Construction

Document Number: EMC

- SOP

- 2027 Page 4 of 7

Title: Control Plan for Line 6 Wet Scrubber System

ROCKDALE OPERATIONS

- SMELTING AND INGOT PAGE 1 OF 5

Document Number: PMT

- SOP

- 2005

Title: Control Plan For Line 3 Wet Scrubber System



### Controlled Document if Viewed On

- Line. If Printed, Valid for 24 Hours from Print Date/Time.

Pri nt Date/Time 2/6/2003 2/5/2003 1:57 PM 1:25 PM 12:59 PM 12:23 PM

Controlled Document if on BLUE PAPER or Viewed On

- Line. If Printed, (except BLUE PAPER) Valid

for 24 Hours from Print Date/Time.

Print Date/Time 5/27/2011 6/24/2004 6/15/2004 9:12 AM 10:00 AM 1:41 PM PROCEDURE TO:

Control Fan Amps

Water Flow

ES P’s

Outlet Emissions

Dust Collecting Hoppers

(continued) Consequences of Deviation

. Abnormal emissions is an indication high gaseous and/or particulates.

Corrective Action

. Initiate corrective action. Refer to MACT Reaction Plan SOP for visible

emissions.



### Dust Collecting Hoppers

Operating Range

. Empty or near empty.

Measurement Method

. Manual tapping everyday and ensuring proper hopper controls and dust

collection.

Control Method

. D PU system operating for ESP’s.

Consequences of Deviation

. Dust backs up into ESP direct current power wires and plates causing a short

which leads to low parametric values causing high outlet emissions and MACT

parametric exceedances.

C orrective Action

. Ensure dust collecting hoppers to be empty and call supervision to have cleaned.

# A Rockdale Operations Standard Operating Procedure

Department Name: Engineering, Maintenance & Construction

Document Number: EMC

- SOP

- 2027 Page 5 of 7

Title: Control Plan for Line 6 Wet Scrubber System

ROCKDALE OPERATIONS

- SMELTING AND INGOT PAGE 1 OF 5

Document Number: PMT

- SOP

- 2005

Title: Control Plan For Line 3 Wet Scrubber System



### Controlled Document if Viewed On

- Line. If Printed, Valid for 24 Hours from Print Date/Time.

Pri nt Date/Time 2/6/2003 2/5/2003 1:57 PM 1:25 PM 12:59 PM 12:23 PM

Controlled Document if on BLUE PAPER or Viewed On

- Line. If Printed, (except BLUE PAPER) Valid

for 24 Hours from Print Date/Time.

Print Date/Time 5/27/2011 6/24/2004 6/15/2004 9:12 AM 10:00 AM 1:41 PM

# A Rockdale Operations Standard Operating Procedure

Department Name: Engineering, Maintenance & Construction

Document Number: EMC

- SOP

- 2027 Page 6 of 7

Title: Control Plan for Line 6 Wet Scrubber System

ROCKDALE OPERATIONS

- SMELTING AND INGOT PAGE 1 OF 5

Document Number: PMT

- SOP

- 2005

Title: Control Plan For Line 3 Wet Scrubber System



### Controlled Document if Viewed On

- Line. If Printed, Valid for 24 Hours from Print Date/Time.

Pri nt Date/Time 2/6/2003 2/5/2003 1:57 PM 1:25 PM 12:59 PM 12:23 PM

Controlled Document if on BLUE PAPER or Viewed On

- Line. If Printed, (except BLUE PAPER) Valid

for 24 Hours from Print Date/Time.

Print Date/Time 5/27/2011 6/24/2004 6/15/2004 9:12 AM 10:00 AM 1:41 PM

# A Rockdale Operations Standard Operating Procedure

Department Name: Engineering, Maintenance & Construction

Document Number: EMC

- SOP

- 2027 Page 7 of 7

Title: Control Plan for Line 6 Wet Scrubber System

ROCKDALE OPERATIONS

- SMELTING AND INGOT PAGE 1 OF 5

Document Number: PMT

- SOP

- 2005

Title: Control Plan For Line 3 Wet Scrubber System



### Controlled Document if Viewed On

- Line. If Printed, Valid for 24 Hours from Print Date/Time.

Pri nt Date/Time 2/6/2003 2/5/2003 1:57 PM 1:25 PM 12:59 PM 12:23 PM

Controlled Document if on BLUE PAPER or Viewed On

- Line. If Printed, (except BLUE PAPER) Valid

for 24 Hours from Print Date/Time.

Print Date/Time 5/27/2011 6/24/2004 6/15/2004 9:12 AM 10:00 AM 1:41 PM